Waste containment system and method for an abrading or cutting device

ABSTRACT

Abrading and cutting devices such as saws include waste containment systems and methods to improve removal of slurry or other contaminants from a work area during operations, and separation of slurry from a carrying medium such as air. A vacuum bar includes high and low vacuum openings to help focus flow and to conserve vacuum pressure. One opening faces the saw blade. A slurry containment and separation container includes walls and configurations for the inlets and outlets that enhance cleaner separation of the air and the slurry. Coolant is applied to the saw blade to make operation and cleanup more efficient. The vacuum generator can operate off of the power generated by the machine.

This application is a divisional of Ser. No. 09,399,297 filed Sep. 17,1999, Pat. No. 6,318,351, issued Nov. 20, 2001. This application isrelated to co-pending application, Ser. No. 09/661,957, filed Sep. 14,2000.

BACKGROUND OF THE INVENTIONS

1. Field of the Invention

The present inventions relate to abrading and cutting devices andmethods, and more specifically to waste containment systems and methodsfor such devices and methods, for example slurry containment systems andmethods for saws, cutters and the like.

2. Related Art

Pavement treatment apparatus and methods are known for concrete andasphalt saws which may include a vacuum apparatus for removing water andparticulate matter, commonly referred to as slurry, from a work site.See Bassols, U.S. Pat. No. 5,564,408, entitled Pavement Treatment Methodand Apparatus, the specification and drawings of which are incorporatedherein by reference. As discussed in that patent, concrete and asphaltsaws are typically used to cut joints for expansion and contraction ofsuch materials in freeway pavement, aircraft runways, and other pavementsurfaces. Typical saws are marketed under different brand names andinclude a diamond blade of different diameters according to thethickness of the pavement to be cut, such as 12, 14, 16, or 24 -inchblades, etc., driven by an internal combustion engine. The engine isalso used to drive a traction mechanism at the rear of the saw foradvancing the saw along the pavement. A belt takes power from a pulleydriven by the internal combustion engine for powering a transmission boxto step down the revolutions per minute (rpm) of the engine to asuitable rate for driving the traction wheels of the saw and for drivingthe saw blade.

The saw blade includes a blade guard for protecting the blade duringoperation and for preventing injury while the blade is rotating. Theblade guard also contains cooling water sprayed onto the blade so thatthe cooling water drops onto the pavement.

The saw also includes a structural support frame for supporting all ofthe components and for mounting the wheels to the saw. The framesupports the engine, the shaft for driving the saw blade, the tractiontransmission and the pulleys for powering the traction transmission fromthe engine, among other elements.

In operation, the saw is started and positioned in alignment with thedesired cutting path, and lowered into engagement with the pavementwhile at the same time turning on the coolant spray to the blade. Anadditional vehicle or other source is located nearby for supplying waterfor cooling the blade through a suitable hose. As cutting continues, thewater and resulting slurry from the abraded pavement is picked up by asuction or vacuum bar to minimize filling previously cut joints. Theslurry and any air picked up by the vacuum bar is taken back to aseparator tank for removing the slurry. A disposal hose transports wastefrom the collection tank through a diaphragm pump to a truck or othercontainer for disposal.

SUMMARY OF THE INVENTIONS

Waste containment systems and methods are described for abrading andcutting apparatus which provide improved removal of slurry and improvedoperating life of various components in the system. Such systems andmethods may be used on saws, such as pavement and concrete saws, othercutting tools, such as wall saws, core drills and other boringequipment, and the like. The systems and methods may be implemented asoriginal equipment or as accessories in kit form or individualcomponents.

In one aspect of one of the inventions, a material pickup element isprovided for picking up a fluid, which may include solid particlesforming a slurry. The pickup element may be a vacuum bar, vacuum shoe orother suction device, for example. Element includes a number of openingscomprising at least one and preferably a set of low vacuum apertures andat least one and preferably a second set of high vacuum apertures. In apreferred embodiment, the high vacuum apertures pickup most if not allof the slurry, and the low vacuum apertures focus, collect, concentrateor align the slurry so that it can be more easily picked up by the highvacuum apertures. For example, the low vacuum apertures can center orbring in fluid from both sides of the vacuum element so that an adjacenthigh vacuum aperture can pickup the slurry. Using both low and highvacuum apertures helps to conserve vacuum pressure, or minimize the lossof vacuum through larger openings, especially where the amount of vacuumavailable is limited or fixed. Conversely, using both low and highvacuum apertures permits placement of high vacuum areas where they maybe most beneficial, and reduction of aperture size at other areas of thepickup element where high vacuum would not have significant incrementalvalue over others already included.

In one preferred form of the pickup element, the low vacuum aperturesare round or similar holes and the high vacuum apertures are extendedslots in the pickup element. The round holes may be grouped in a series,and the round holes may be co-linear with a slot. Other configurations,arrangements and orientations for the openings can be used.

In one preferred aspect of one of the inventions, the pickup element isused on a concrete or similar saw which moves along the work surface.The openings are preferably distributed over the pickup element so as totake advantage of the forward or backward motion of the saw. In onepreferred embodiment, the high vacuum apertures are placed in front ofthe low vacuum apertures, which in turn may be followed by one or moreadditional high vacuum apertures. Alternatively, high and low vacuumapertures may alternate along the pickup element, for example beginningand ending with high vacuum apertures. The pickup element can then bringin fluid from both sides of the element, minimize or limit flow over thework surface and tailor the location or flow of the slurry relative tothe pickup element.

In a further preferred aspect of one of the inventions, one or more ofthe apertures or openings may extend along a surface of the pickupelement in a direction at least partly perpendicular to the worksurface. For example, in a vacuum bar that extends horizontally, most ofthe apertures can open downwardly and extend horizontally over ahorizontal surface of the vacuum bar and a high vacuum aperture canextend vertically or in a direction other than downwardly. A verticallyextending high vacuum aperture can be advantageous directly behind thesaw blade.

In a further aspect of one of the inventions, a system can be used fordesigning pickup elements. The system can include a processor orcomputer loaded with a computational fluid dynamics fluid flowoptimizing program to optimize the flow of the slurry and maximize thesuction created by the fan. Input parameters include maximum vacuumavailable, desired fluid flow rates through the pickup element, and thelike. The system preferably identifies possible as well as optimum sizesand configurations for pickup elements, and potential and optimum sizes,configurations and distributions of vacuum openings. In one preferredembodiment, the system is used to identify the sizes, shapes andlocations of openings to be used for picking up slurry, in addition tothe sizes, shapes and locations of openings to be used for focusing,channeling or otherwise controlling flow of the slurry away from thepickup element.

In a further aspect of one of the inventions, the pickup element caninclude removable end caps having curved surfaces for more easilynegotiating or riding over pebbles or other objects which may be in theline of travel. Having removable end caps makes for easier cleaning ofthe pickup element.

In another aspect of one of the inventions, a tool guard such as a bladeguard includes a water supply conduit or tube for projecting or sprayingfluid onto the tool. The fluid may be used as a lubricant and/or coolantfor the tool. The fluid is directed toward the tool at an angledifferent than 90 degrees. For example, the fluid can be directedbackward toward an on-coming surface of the tool. Directing the fluidbackward relative to the motion of the tool reduces the amount of fluidthrown forward of the tool. Consequently, the amount of fluid to bepicked up at the front of the tool is reduced. In one preferredembodiment, the fluid is directed backward about three degrees from aline perpendicular to the tool, such as a blade.

In a further aspect of one of the inventions, a separation system andmethod are provided for separating air and a second fluid. A receptacleis provided for receiving a combination of air and the second fluid, thereceptacle including at least two vertically extending walls joining ata vertically extending angle. An inlet receives a combination of air andthe second fluid and allows the combination to flow into the receptacle.A first outlet passes the second fluid from the receptacle and a secondoutlet passes air from the receptacle. This configuration contributes toproviding a receptacle which more completely separates the air from thesecond fluid. This configuration makes the flow and disposition of thesecond material more controlled or organized, while promoting moreuncontrolled or disorganized air flow. This type of receptacleconfiguration also reduces any tendency toward cyclone-type action inthe fluid flow, for the air and for the second fluid. It also reducesthe amount of symmetry in the surfaces in the receptacle, and incombination with other features, reduces residual splashing of thesecond fluid.

In another aspect of one of the present inventions, an inlet for aseparation system discharges the air and fluid combination closer to thebottom of the receptacle than to the top. With this configuration, thefluid has a shorter distance to travel to the bottom of the receptacle,reducing the amount of splashing and reducing the amount of time themoving air from the inlet is around the moving fluid from the inlet.Additionally, when the outlet for the air is at the top of thereceptacle, the air will have more time and area for shedding fluidbefore leaving the receptacle.

Consequently, the air leaving the receptacle has a lower fluid content.Furthermore, where the fluid has abrasive, corrosive or other harmfulmaterial, the amount of harmful material leaving the receptacle throughthe air outlet and reaching other components is reduced.

In an additional aspect of one of the present inventions, an air outletfor a receptacle in a separation system is positioned off of a line,axis or plane of symmetry. Positioning of the air outlet in this wayremoves air that is less controlled or less organized earlier than airin other locations of the receptacle where the air may be morechanneled. In one preferred embodiment, the only plane or line ofsymmetry for the air outlet is one between vertically extending walls ofthe receptacle. Locating the air outlet on this plane of symmetryreduces the possibility of exiting air pulling with it condensed fluidfrom either of the walls.

In a further aspect of one of the present inventions, an inlet for aseparation system discharges an air and fluid combination into areceptacle between two vertically extending walls, and closer to onevertically extending wall than to the other. This asymmetry tends toreduce splashing of the second fluid and contributes to greater control,containment or organization of the second fluid.

In one aspect of the present inventions, a tool is provided for workinga material, such as cutting concrete, where the tool is driven by adrive element, such as a drive shaft. Vacuum is created by a vacuumgenerator driven by the same drive shaft that drives the tool. Such adesign provides for a compact and self-contained combination of tool andwaste containment system. The design also makes it easier to assemblethe combination as a tool and kit for easy assembly and disassembly.

These and other aspects of the present inventions will be betterunderstood after a consideration of the drawings, a brief description ofwhich follows, and the detailed description of the preferred embodimentsof the inventions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a left front isometric view of a cutting device in the form ofa saw incorporating a waste containment system in accordance withseveral aspects of the present inventions.

FIG. 2 is a top plan view of the saw of FIG. 1.

FIG. 3 is a right side elevation view of the saw of FIG. 1.

FIG. 4 is a left side elevation view of the saw of FIG. 1.

FIG. 5 is a schematic and flow diagram showing the flow of air andfluids through a waste containment system in accordance with severalaspects of the present inventions.

FIG. 6 is a lower left front isometric view of a blade guard support inaccordance with another aspect of the present inventions.

FIG. 7 is a bottom plan view of the blade guard support of FIG. 6.

FIG. 8 is a left front isometric view of a material pickup element suchas a vacuum bar in the accordance with a further aspect of one of thepresent inventions.

FIG. 9 is a bottom plan view of the vacuum bar of FIG. 8 showing highvacuum and low vacuum openings.

FIG. 10 is a left side elevation view of a container and pump for usewith the containment system of FIG. 1.

FIG. 11 is a vertical cross-sectional view of the left side of thecontainer and pump of FIG. 10 showing an air and slurry input, a wasteoutput and an air output.

FIG. 12 is a horizontal cross-sectional view of the top of the containerand pump of FIG. 10 showing the slurry input, the air output and amounting assembly.

FIG. 13 is an upper right isometric view of the container and pump ofFIG. 10.

FIG. 14 is a partial left elevation view of the saw of FIG. 1 showing avacuum generator and its drive mechanism.

FIG. 15 is a right side isometric view of the vacuum generator and itsdrive transmission assembly and mounting assembly.

FIG. 16 is a right side elevation view of the assemblies of FIG. 15.

FIG. 17 is a side elevation view and partial cut-away of a blade guardshowing water tubes for wetting the saw blade.

FIG. 17A is a detail of a water tube of FIG. 17.

FIG. 18 is a bottom plan view of a vacuum bar having a furtherarrangement of openings.

FIG. 19 is a bottom plan view of a vacuum bar having another arrangementof openings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following specification taken in conjunction with the drawings setsforth the preferred embodiments of the present inventions in such amanner that any person skilled in the art can make and use theinventions. The embodiments of the inventions disclosed herein are thebest modes contemplated by the inventor for carrying out the inventionsin a commercial environment, although it should be understood thatvarious modifications can be accomplished within the parameters of thepresent inventions.

In accordance with several aspects of the present inventions, a wastecontainment system and method are provided for abrading, cutting orcoring machines. While the description herein will be directed primarilyto cutting machines, and while the preferred embodiments will bedescribed with respect to applications to concrete saws, it should beunderstood that the inventions can be applied to any number applicationsother than concrete saws and other cutting machines. The concepts areapplicable to other machines in a manner similar to how they would beapplied to concrete saws as described herein. For example, the high andlow vacuum openings on a material pickup element can be applied to anynumber applications, while they are especially pertinent to those wherethe amount of vacuum is limited or fixed. As another example, theseparation receptacle can take any number of configurations given theconcepts described herein. Moreover, other aspects of the inventionsdescribed herein can be used in any number of applications.

A waste containment system and method on a concrete saw in accordancewith various aspects of the present inventions provide an efficient andreliable apparatus and method for limiting or entirely removing anywaste material created or generated while cutting concrete. The systemand method removes a substantial amount of water or other coolantproduced during the cutting process. The vacuum used to remove theslurry can be easily generated through the engine or other power planton the saw without noticeably reducing its output. Waste material can bereliably removed from the vacuum system so as to reduce contamination orfouling of components, and to give an acceptable operating lifetime tothe components. The system and methods can be implemented as a completeproduct or as individual components, such as in kit form. All parts canbe made removable, and they can be used to retrofit many existing saws.

In accordance with one aspect of the present inventions, a concrete saw300 (FIG. 1) includes a frame or chassis 302 supporting an engine, shownschematically as 304, for driving a saw blade 306 through a drive shaft308. The engine and the drive shaft, as well as other transmissioncomponents, also drive and power other components of the saw, as isknown to those skilled in the art of concrete saws. The saw and sawblade can also be powered and driven by an electric motor, and all ofthe components on it can be driven or energized electrically.

The saw also includes a material pickup element in the form of a vacuumbar 310 to which is coupled a preferably 2 inch diameter vacuum hose 312for removing a slurry of water and particulates created during cutting.Water is provided through a conduit (not shown) to the inside of theblade guard 314 to act as a coolant for the blade 306. The particulatesare typically bits of concrete both large and small produced duringcutting. Other waste material will be produced using other equipment ondifferent work surfaces, but many of the concepts described herein willbe similarly applicable. The blade guard 314 is preferably similar oridentical to a blade guard described in U.S. Pat No. 5,564,408, and issupported by a blade guard mount 316, shown in FIG. 1 configured formounting on a saw such as that manufactured by Cushion Cut. The bladeguard includes a top mounted handle 318 for ease of access.

The vacuum hose 312 extends as short a distance as possible to a slurryrecovery and separation assembly 320 (FIG. 2) for transporting theslurry from the vacuum bar 310 to the assembly 320. The vacuum hose 312is preferably raised as little as possible above the level of the vacuumbar 310 so as to use as little vacuum as possible raising the slurry tothe level of the assembly 320. The assembly 320 is preferably located ona side or a surface of the saw 300 different from the right side wherethe blade is located so as not to obstruct the view that the operatorhas of the cutting area.

Vacuum is created in the assembly 320, and therefore through the vacuumhose 312 and in the vacuum bar 310, through a vacuum generator 322coupled to the assembly 320 through a vacuum hose 324. The vacuumgenerator 322 is driven by the drive shaft 308, as discussed more fullybelow, and is controlled by the revolutions per minute (rpm) of thedrive shaft. Alternatively, where the saw is electrically powered, thevacuum generator could be driven by current from the saw motor.

Waste is removed from the assembly 320 through a waste pipe 326 througha pump 328 (FIG. 12) operated by a motor 330. The pump 328 is similar tothat described in U.S. Pat. No. 5,564,408 but includes metal reinforcingon several of the moving parts of the pump. The motor 330 is preferablyan electric motor driven by current developed in an alternator orgenerator on the engine 304. The pump also preferably includesconventional flap valves to control flow and prevent back flow on eachside of the pump.

The vacuum bar 310, modified blade guard 314, vacuum hose 312, assembly320 and the vacuum generator 322 may be factory installed or produced ascomponents for a kit or for retrofit on existing saws. The remainingcomponents of the saw are typical, and do not require enhancements orextraordinary modifications. Some of the other typical components of thesaw are illustrated for context such as the display panel 332 andhandles 334. While enhancements can be made to the basic saw to furtheroptimize the operation, for example with larger saw blades, it is notbelieved that such modifications are necessary for proper operation.

The blade guard support 316 (FIGS. 1, 6 and 7) is similar to thatdescribed in U.S. Pat No. 5,564,408, and includes a spacer 336 having awidth defining the spacing between the left plate 338 and right plate340, but also a depth 342 to provide more strength to withstand bendingor buckling of the plates 338 and 340. A mounting holster 344 acceptsthe support element of the saw for supporting the blade guard.

The vacuum bar 310 (FIGS. 8 and 9) for picking up the slurry from aroundthe saw blade and from grooves is similar to the vacuum bar described inU.S. Pat No. 5,564,408 in the context of concrete saws. The vacuum baris supported by the blade guard and held stationary relative to theblade guard by a mounting plate 346 through a mounting bolt (not shown).The position of the vacuum bar relative to the blade guard can beadjusted through the mounting bolt for adjusting the spacing between thebottom of the vacuum bar and the work surface. The preferred spacing foreffective pickup of slurry from the work surface may depend on a numberof factors such as the size of the vacuum bar and the number openings,as well as the vacuum developed at the vacuum bar and the surfacemakeup. The spacing will also depend on the uniformity of the worksurface and how much large debris is created during cutting. Forconcrete, the spacing may be about {fraction (1/16)}^(th)(one-sixteenth) of an inch, and greater for asphalt.

The vacuum bar is also supported or stabilized by a left side wall 348and a U-shaped internal blade guard wall 350. The left side wall 348 iswelded or otherwise mounted to the mounting plate 346 and to the top ofthe vacuum bar manifold 352, as well as to the left vacuum tube 354adjacent an inner side surface 356. The right side and rear of the wall350 are mounted to the top surfaces of the right vacuum tube 358 andmanifold 352, respectively. Part of the left side of the wall 350 iswelded to the top of the left vacuum tube 354, and a remainder extendsbetween the right vacuum tube 358 and the left vacuum tube 354 (FIG. 9).Various reinforcing walls can also be included. The vacuum coupling 360is mounted to the top of the manifold 352 for accepting the vacuum hose312. The tail 362 of the vacuum bar extends rearwardly from the centerof the manifold 352. The left side vacuum tube 364 extends at an anglefrom the left vacuum tube 354 to the left side and toward the front, andthe right side vacuum tube 366 extends to the right side from the rightvacuum tube 358 and toward the front. The left side vacuum tube 364joins the left vacuum tube 354 at a point forward of the manifold 352 inorder to make room for other hardware on the saw.

As shown in FIGS. 8 and 9, the vacuum bar 310 defines a housingbeginning with the manifold 352 and having a plurality of housing wallssuch as the top 368 of the manifold, the bottom wall 370 of themanifold, and a front manifold wall 372. The housing of the vacuum baralso includes a first housing wall 374 defining the right vacuum tube358 and comprising a top wall 376, a left side wall 378, a right sidewall 388, and a bottom wall 382, and closed off by-a preferablyremovable end cap (FIG. 8A). The first housing wall 374 is shown havinga square, longitudinally extending configuration or cross-sectiondefining a channel 390 closed by the end cap on one end and joining themanifold at the other end adjacent the forward wall 372. Otherconfigurations are possible, but a square cross-section is preferred toenhance pickup and transport of the slurry. The other vacuum tubes arealso preferably square in cross-section.

The bottom wall 382 includes a plurality of opening walls defining aplurality of apertures passing through the bottom wall 382 to permit apressure differential across the bottom wall between the channel 390 andthe outside of the tube 358 when vacuum is applied to the vacuumcoupling 360. The plurality of apertures includes at least one lowvacuum aperture 392 and at least one high vacuum aperture 394. The highvacuum aperture picks up most if not all of the slurry in its region andthe low vacuum aperture focuses, collects concentrates or aligns theslurry so that it can be more easily picked up by a high vacuumaperture, typically a different high vacuum aperture. Some pickup mayoccur with the low vacuum apertures. It is believed that the low vacuumapertures center or bring in fluid from both sides of the vacuum bar sothat it can be picked up by a high vacuum aperture following behind. Forexample, a trailing high vacuum aperture 396 generally aligned with thepreceding low vacuum apertures 392 will pickup the slurry gathered bythe apertures 392. The trailing high vacuum aperture 396 is formed inthe bottom wall 370 of the manifold. Additionally, though notnecessarily, a side high vacuum aperture 398 formed in the bottomsurface or wall 400 of the right side vacuum bar 366 may also pickupslurry gathered by the low vacuum apertures 392. It should be noted thataperture 398 will also pickup water splashed away from the saw blade,which would not typically include any particulates generated duringcutting.

Using high vacuum and low vacuum apertures helps to conserve vacuumpressure or minimize the loss of vacuum through larger openings,especially where the amount of vacuum available may be limited by thesize of the saw, available horsepower, and the like. They are alsohelpfil, for a given size of saw, where larger blades are used in placeof smaller blades. With a larger blade, the vacuum bar 310 is longer inoverall dimension, preferably extending at least to the front of theblade guard if not further forward. For a given saw, a 30 inch bladewould preferably include a vacuum bar 310A (FIG. 18) that was about 44or 45 inches long, whereas the suction bar shown in FIGS. 8 and 9 wasdesigned for a 16 inch blade and is about 27 or 28 inches long. A 26inch blade would preferably include a vacuum bar 310B (FIG. 19) that wasabout 38 or 40 inches long. Additionally, having both low and highvacuum apertures allows positioning of the high vacuum apertures atlocations of high slurry and/or water production, and positioning of lowvacuum apertures elsewhere where high vacuum is not as important.Nonetheless, the low vacuum apertures still help to collect the slurryto be picked up by a following or trailing high vacuum aperture.

In one preferred aspect of the present inventions, the low vacuumapertures are round or similarly shaped holes having walls 402, 404 and406. The holes are preferably formed straight through the bottom wall382 of the housing 374 perpendicular to the surface of the housing.However, the configurations of the holes can be different, as well asdifferent from each other, in size, shape, positioning and orientation.For example, the low vacuum holes can be arranged in a series such asthose shown in FIG. 9, aligned with one another, and also aligned withthe end of the high vacuum aperture 394. The first one or several lowvacuum holes, for example, can be the same size while following holestoward the rear of the vacuum bar can be larger in size, and thereforehigher in vacuum. Conversely, they can decrease in size in the samedirection. Additionally, the apertures can be placed other than in thecenter of the bottom wall 382.

In another preferred aspect of the present inventions, the high vacuumapertures are extended slots defined by substantially straight walls 408joined by substantially circular end walls 410. The high vacuumapertures are also preferably formed straight through the bottom wall382 of the housing 374 perpendicular to the surface. As with the lowvacuum apertures, the high vacuum apertures can be different as well asdifferent from each other in size, shape, position and orientation, andmay vary in size from one end to the other of an individual slot.

The apertures, such as the high vacuum apertures, can be curved such asthe high vacuum apertures 396 in the manifold 352. They also can haveother shapes. The aperture 396 extends almost the entire length of themanifold and curves toward longitudinal center line of the manifold.Additionally, as can be seen in FIG. 9, a high vacuum aperture such as396 can be formed from two or more openings, including 398. A secondhigh vacuum aperture 412 may be formed from a long slot and twooppositely extending short slots. Additional high vacuum apertures 414and 416 are preferably formed in the bottom wall 370 of the manifold andthe bottom wall of the tail 362 of the vacuum bar, respectively,preferably aligned with the plane of the saw blade to remove slurry notonly from the work surface but also the groove just cut.

The high vacuum aperture 414 is formed from a slot in the bottom 370 inthe manifold and from a slot 418 (FIG. 8) formed in a vertical forwardwall 372 of the manifold. As can be seen, a high vacuum aperture can beformed in two different surfaces of the vacuum bar. The slot 418 can beformed as its own high vacuum aperture positioned directly behind sawblade to pickup material thrown up by the saw blade. However, it isbelieved that a continuous high vacuum aperture formed by the slot 418and the slot 414 is more effective at picking up slurry immediatelybehind the saw blade. The slot 418 can be wider than the other highvacuum slots, as can other high vacuum slots immediately behind theblade, or they can be the same width.

The first housing wall 374 may also include an additional high vacuumaperture 418 at a forward portion 420 of the first housing 374. Theaperture 418 would be the forward-most aperture on the right side of thevacuum bar to be able to pickup water or slurry from the work surface.In the preferred embodiment, three low vacuum apertures 422 arepositioned close behind and aligned with the high vacuum aperture 418.

In the preferred embodiment, the left vacuum bar 354 forms a secondhousing element 424 in fluid communication with the manifold and thefirst housing wall 374, extending forward of the manifold and slightlydivergent from the first housing wall 374. The second housing element424 also preferably includes a forward high vacuum aperture 426 to bethe forward-most high vacuum aperture on the left side of the vacuumbar. It also includes a set or series of low vacuum apertures 428preferably aligned with and rearward of the high vacuum aperture 426. Anadditional high vacuum aperture 430 may be formed between the low vacuumapertures 428 and the manifold 352.

As can be seen in FIG. 9, the high vacuum and low vacuum apertures canalternate and can be aligned with respect each other, preferably in thegeneral direction of travel of the vacuum bar. The openings arepreferably distributed over the vacuum bar so as to take advantage ofthe forward or backward motion of the saw. The different openingspromote more even flow of the slurry relative to the vacuum bar andconserve vacuum pressure. The high vacuum and low vacuum apertures mayalternate between a single large opening and a series of small openings,again followed by a large opening. The actual distribution,configuration and arrangement of the different apertures may bedetermined by a fluid dynamics computer program based on various inputparameters, including available vacuum or suction, viscosity, desiredflow rates, and the like. The openings are also given, typically, andthe system works iteratively to develop possible solutions. While mostof the apertures open downwardly from the bottom of the vacuum bartoward the work surface, at least one aperture 414 includes a portion(slot 418) that extends vertically, opening or facing other thandownwardly. In one preferred embodiment, the low vacuum apertures are0.125 in. in diameter (less a few thousandths of an inch for a powdercoating on the vacuum bar) and separated from each other by about 0.750in. They are preferably arranged in series of three. The width of thehigh vacuum apertures is preferably 0.125 in., and their length mayrange from less than an inch to several inches, depending on the lengthof the vacuum bar. The vacuum bar for a 16 in. saw blade can have highvacuum aperture lengths up to four or five inches or more for vacuumdeveloped with a conventional saw with the system described herein.

FIG. 8A shows a bull-nosed end cap 432 for closing off the forward endsof the left and the right vacuum tubes and the rearward end of tube 362.The bull nose shape includes curved surfaces 434 for more easilynegotiating or riding over pebbles or other objects which may be in theline of travel, such as created during cutting. The end caps areremovable for easier cleaning of the vacuum bar.

The slurry recovery and separation assembly 320 (FIGS. 10-13) separatesthe air from the water coming from the vacuum hose 312, and thereforeremoves abrasive material from the air. Other damaging materials mayalso be present in the slurry, which are preferably removed from theair. The assembly 320 preferably includes a fluid-tight receptacle,container, canister or tank 436 for receiving a combination of the airand slurry, and including at least two vertically extending walls, suchas right side wall 438 and front exit wall 440. The two walls meet andjoin at a vertically extending 90 degree angle 442 so that the potentialfor the air and slurry within the tank 436 to rotate or create acyclone-type motion is reduced. The left side wall 444, similar in shapeto the right side wall 438, also extends vertically and joins the frontexit wall 440 at a vertically extending angle 446. Both of the left andright side walls meet and join a back inlet wall 448 at respectivevertically extending angles or corners 450 and 452, respectively. Thetank 436 is closed by a top or cover 454 which joins the respective sidewalls at 90 degree angles at a support flange 456 extending around theperimeter of the tank. It is removable for easy cleaning of the tank.The tank 436 preferably does not have a flat, horizontal bottom, toreduce splashing. The remaining walls between the left and right sidewalls are generally square or rectangular, join the respective sidewalls at 90 degree angles, preferably, but are arranged more or lesshorizontally or vertically as a function of location relative to aninlet or an outlet.

The back inlet wall 448 extends vertically a substantial portion of theheight of the tank 436. The bottom joins a first shelf plate 458 at anangle 460 of approximately 100 degrees for allowing liquid to flow downthe first shelf plate 458. The first shelf plate 458 slopes to a lowershelf plate 462. The first shelf plate 458 and the lower shelf plate 462join at an angle 464 of approximately 200 degrees to minimize upwardsplashing of slurry, and to move slurry down to the bottom of the lowershelf plate 462 where it collects. The lower shelf plate 462 ends at andis supported by a pump support plate 464 and joins a slurry outlet plate466 at an angle 468 of approximately 30 degrees, a small acute angle.This angle is relatively small so as to effectively retain the slurry inthe relatively narrow bottom until it is pumped out by the pump 328through a slurry outlet 470 located close to and connected to the pumpby a short tube of about several inches. The slurry outlet plate 466extends upwardly and rearwardly to approximately the same level as angle464, where it joins a riser plate 472 at an angle 474 of approximately223 degrees. The angle 474 is preferably greater than 180 degrees so asto increase the volume of the mid-level portion of the tank, or thatportion of the volume of the tank between angle 474 and the top of theriser plate 472 and the back inlet wall 448, while still presenting asplash plate or wall tending to keep the slurry and any excess waterbetween plates 462 and 466. The riser plate 472 is preferably at about a15 degree angle from the vertical to provide a vertically extending wallfor minimizing splashing while still providing an increasing volume inthe upward direction and interrupting any direct line of air flow fromthe inlet to the air outlet. The riser plate 472 extends away from theback inlet wall 448 to allow air to travel more easily upward and awayfrom the slurry.

The riser plate 472 joins an upper shelf plate 476 at an angle 478 ofapproximately 249 degrees. The upper shelf plate 476 extends forward tovertical front exit wall 440 where they join at an angle 480. The uppershelf plate 476 provides the base portion of the upper approximateone-third of the tank, measured vertically. The upper third of the tankpreferably contains almost all air and very little moisture or slurry.The intermediate approximate one-third of the tank, measured vertically,will have a substantial portion of air and some water or slurry. Thelower one-third, measured vertically, preferably has almost exclusivelyslurry. The depth of the slurry is preferably about 3 to 3½ inches.

The tank includes an inlet 482 for receiving a combination of air andslurry from the vacuum hose 312 and allowing the combination of air andslurry to flow into the tank. The inlet passes through the back inletwall 448. The inlet 482 is preferably a relatively rigid tube or pipe484 and extends a substantial distance from the wall 448 toward theriser plate 472 to a 90 degree elbow 486. The elbow 486 terminates in awall 488 defining an opening 490 preferably facing directly downwardtoward lower shelf plate 462 for allowing the slurry to drop straightdown. The opening 490 is preferably positioned below the upper shelfplate 476 so that there is no direct line of air flow between theopening 490 and the air outlet. The opening 490 as well as the rest ofthe inlet 482 are preferably two inches in diameter and may pass anapproximately 3:1 ratio of air to slurry by cross-sectional area atabout 200 cubic feet per minute. The opening 490 is positionedsignificantly below the upper shelf plate 476 so that the water andslurry are input well below the upper third of the tank. The inlet 482is preferably centered between the left and right side walls.Additionally, the slurry is preferably input closer to the riser plate472 than to the inlet plate 448 so that the slurry travels as little aspossible before reaching the bottom of the tank and the slurry outlet470. The opening 490 is preferably high enough above the slurry levelthat vacuum is still created in the vacuum line 312 without creatingturbulence on the surface of the slurry at the bottom of the tank, whileat the same time minimizing the height that the slurry must be raisedfrom the suction bar to the inlet 482.

A second, air outlet 492 removes air from the tank 436 thereby creatinga vacuum within the tank, which creates a vacuum within the vacuum hose312 for producing suction in the suction bar 310. The air outlet 492 ispreferably centered between the side walls and located close to the airoutlet wall 440 and a significant distance from the slurry in the bottomof the tank. The air outlet is not located on any line or plane ofsymmetry other than between the two side walls thereby reducing thepossibility that air being removed from the tank is part of a channel ofair flow. The air travels a significant distance through the tank toreach the outlet, and does not have a direct line of travel between theopening 490 and the outlet 492. The outlet 492 includes a wall 494 fordefining an opening 496 which is preferably flush with the top 454 ofthe tank.

The separation tank promotes organized control of the slurry anddisorganized or uncontrolled flow of air within the tank. The irregularsurfaces and discontinuous walls in the tank reduces cyclone-type fluidflow within the tank which would tend to keep moisture and particulatescarried in the air. The inlet is placed close to the slurry or othermaterial outlet and close to a wall to help contain the material flow.Residual splashing is minimized as much as possible by interrupting anystraight or parabolic air path and any air flow channels, and reducingsymmetries of surfaces within the tank, while encouraging a gentlegradient of air flow from the area of the inlet portion of the tank tothe outlet portion of the tank. Additionally, it is preferred tominimize the amount of directional change of the air and slurry comingout of the opening 490. It is also preferred to place the inlet openingfar enough away from any given surface to minimize funneling orchanneling of air upward past the opening 490. One measure of onepreferred inlet position is to have a relatively large change incross-sectional area going from the opening 490 into the open tank andreducing the velocity of the air and slurry mixtures. Additionally, alarge total volume for the tank is preferred.

Some exemplary approximate dimensions for the separation tank have thewidth equal to about 9 and ½ in. and the overall length about 27 inches.The inlet wall is about 12 inches high and height from the pump supportplate 464 to the top of the tank is about 18 inches. The plate 440 isabout five inches high, the plate 476 about 13 inches long and the plate472 about eight inches long. The plate 466 is about four inches long andthe plate 462 about eight inches long. The plate 458 is about seveninches long. The length of the inlet 482 from the center of the opening490 to the outer most point of the pipe outside the tank is about 13 and½ inches. These dimensions give a tank having a low height, large volumeand a relatively large transition from the inlet pipe to the tank.

A level indicator or overflow alarm (not shown) can be included toindicate when the level of slurry reaches a selected level. Otherindicators and safety features can be included as desired to make easierbecoming familiar with a machine and for using the machine.

Power to the pump 328 is provided by a sealed conductor 498 extendingfrom a fast hook-up and disconnect junction and switch box 500, mountedat the inlet panel 448, to the pump 328. The conductor extends through asealed opening in the panel 466. A shut-off switch 502 can be used tostart or stop the pump.

A mounting plate 504 (FIGS. 13 and 14) can be fastened to the side ofthe saw so that the separation tank and pump assembly can be removablymounted to the saw through hooks or other brackets 506. The plate andhooks are preferably configured to insure that the separation tank andpump assembly maintain a center of gravity for the tank.

The vacuum generator 322 includes a housing 508 (FIG. 1) for containingan impeller or fan 510 (FIGS. 15-17) for creating a vacuum in the tank.The fan may be a Breuer Electric Mfg. Tornado with a number 12692impeller capable of generating at least 180 to 184 cubic feet per minuteof flow, or more, at 16,500 rpm through a two inch diameter orifice. Thefan is preferably rated for fifty-one inches of static water lift. Thefan chamber part number 12642 and the fan chamber plate part number11237 are also included. The fan is driven off of the saw blade driveshaft 308 through a pulley 512 which drives a second pulley 514, whichin turn drives the shaft 516 of the fan. The fan exhaust 518 is directedinto the housing 508 for cooling the high speed bearings and/orcomponents of the saw.

The fan and two idlers (one for each drive belt, not shown) are eachsupported by two high speed, long life and lifetime lubricated bearingsmounted, supported and protected on the saw frame by suitable supports.The bearings are preferably rated for at least the 16,500 rpm operatingconditions, and preferably higher. The preferred bearings are SKF Mfg.number 6202-2Z/C3HT bearings rated for 29,000 rpm.

The tool guard such as the blade guard 314 includes a water supplyconduit or tube 520 for projecting or spraying fluid onto the saw blade(FIG. 17). The tube 520 preferably includes at least one opening 521,and preferably multiple openings, for projecting fluid out of the tubetoward the blade. Each opening is formed or defined in the tube by arespective wall 521A (FIG. 17A). The water is directed toward the toolat an angle different than 90 degrees. For example, the water can bedirected backward toward the rotationally-advancing side of the blade.Directing the water backward relative to the rotation of the bladereduces the amount of water thrown forward of the blade. Consequently,the amount of water to be picked up at the front of the blade isreduced. In one preferred embodiment, the water is directed backwardalong a line 522 at an angle 522A of about three degrees from a line 524perpendicular to the blade.

By including a vacuum generator on the saw driven by the saw engine orother power supply, the components of the saw can still be part of aself-contained unit. The vacuum generator can operate and produce thedesired vacuum under a number of different conditions, such as differentsaw blade sizes, cutting speeds and the like. The vacuum generator canalso be easily mounted on and removed from the saw along with the otherslurry containment components. The separation tank, the suction bar, thepump assembly, blade guard and vacuum hose can be easily installed onexisting saws and removed if desired. The components can be madeavailable in kit form or installed at the factory.

The waste containment and separation system can be used in otherapplications beyond concrete saws. Wall saws, grinding heads and coredrills also produce particulates that can be contained throughapplication of one or more of the concepts described herein. Forexample, using high and low vacuum apertures in a pickup elementconserves vacuum pressure and permits a selective arrangement of highvacuum pickup locations. Vacuum generators can also be driven off of thedrive elements of the tools, if desired. Additionally, the conceptsdeveloped for separating air from a slurry for maintaining the integrityof the vacuum generator can be applied to other applications. The amountof feedback of damaging particulates or other contaminants can bereduced, thereby extending the life of many components. Filters may notbe necessary, as they reduce the vacuum and produce drag.

Having thus described several exemplary implementations of theinvention, it will be apparent that various alterations andmodifications can be made without departing from the inventions or theconcepts discussed herein. Such operations and modifications, though notexpressly described above, are nonetheless intended and implied to bewithin the spirit and scope of the inventions. Accordingly, theforegoing description is intended to be illustrative only.

What is claimed is:
 1. A blade guard for a saw blade rotating in a givendirection, the blade guard comprising: first and second side-walls foraccepting a saw blade between them; an upper wall extending between thefirst and second side walls; and a water supply conduit extending alongat least one of the first and second side walls for projecting a fluidtoward a side of the blade, wherein the conduit includes at least onewall formed in the conduit forming an opening for projecting fluidtoward the side of the blade and wherein the opening includes a centralaxis extending toward the blade and at an angle to the blade differentthan ninety degrees and against the direction of rotation of the blade.2. The blade guard of claim 1 wherein the angle is about three degrees.3. The blade guard of claim 2 wherein the blade guard has a front and aback and wherein the fluid is projected slightly rearwardly.
 4. Theblade guard of claim 1 wherein the blade guard has a front and a backand wherein the angle of the axis is such that the fluid is projectedslightly rearwardly.
 5. A blade guard for a saw blade rotating in adirection of rotation, the blade guard comprising: first and secondside-walls each having respective rear portions, the side walls beingspaced apart sufficiently for accepting a saw blade between them; anupper wall extending between the first and second side walls; and atleast two water supply conduits extending from the rear portions of thefirst and second side-walls along respective ones of the first andsecond side walls and below the upper wall for projecting a fluid towarda side of the blade, wherein at least one of the conduits includes atleast one wall formed in the conduit and forming an opening forprojecting fluid toward the side of the blade and wherein the openingincludes a central axis extending toward the blade and against thedirection of rotation of the blade and at an angle to the bladedifferent than ninety degrees.
 6. The blade guard of claim 5 wherein theangle is about three degrees.
 7. The blade guard of claim 6 wherein theblade guard has a front and a back and wherein the fluid is projected atleast partly rearwardly.
 8. The blade guard of claim 5 wherein the bladeguard has a front and a back and wherein the angle of the axis is suchthat the fluid is projected at least partly rearwardly.
 9. The bladeguard of claim 5 wherein the conduits each include a plurality of wallsdefining openings for projecting a fluid toward the blade.
 10. The bladeguard of claim 5 wherein the conduits extend from points adjacent therespective rear portions of the first and second side walls and betweenthe side walls to a forward portion of the blade guard so that theopenings are closer to a front of the blade guard than to a back of theblade guard.
 11. A blade guard for a saw blade, the blade guardcomprising: first and second side-walls each having respective rearportions, the side walls being spaced apart sufficiently for accepting asaw blade between them; an upper wall extending between the first andsecond side walls; and two water supply conduits extending from the rearportions of the first and second side-walls along respective ones of thefirst and second side walls and below the upper wall for projecting afluid toward a side of the blade, wherein each of the conduits includesat least one wall formed in the conduit and forming an opening forprojecting fluid toward the blade and wherein the opening includes acentral axis extending toward the blade and at an approximate threedegree angle to the blade.
 12. A blade guard for a saw blade thatrotates in a given direction, the blade guard comprising: first andsecond side-walls for accepting a saw blade between them; an upper wallextending between the first and second side walls; and a water supplyconduit extending along at least one of the first and second side wallsand below the upper wall for projecting a fluid toward a side of theblade, wherein the conduit includes means for projecting fluid towardthe blade in a direction against the rotation of the blade.